mercury, 200-verado, 225-verado, 250-verado, 275-verado

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet,K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waveslogo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury ProductProtection logo is a registered service mark of Brunswick Corporation.

Page 1 / 51 © 2004 Mercury Marine 90-10238051 JUNE 2004

200/225/250/275 VERADO 4-STROKEINSTALLATION MANUALTable of Contents Notice to Installer ................................................... 2Avoiding Loss of Throttle and Shift Control ........... 2Accessory Electric Fuel Pump/Fuel Line PrimerBulb ....................................................................... 2Avoiding Fuel Flow Restriction .............................. 2Boat Horsepower Capacity .................................... 2Selecting Accessories For Your Outboard ............ 3Fuel Tanks ............................................................. 3

Portable Fuel Tank ........................................... 3Permanent Fuel Tank ....................................... 3

Determining Recommended Outboard MountingHeight .................................................................... 4Installing Outboard ................................................ 5

Installation Specifications..................................5Maximum Outboard Mounting Height................5Drilling Outboard Mounting Holes......................6Lifting Outboard.................................................7Fastening Outboard...........................................8

Power Steering Installation .................................. 10Power Steering System...................................10Installation Procedure......................................10Connection of the Hydraulic Hoses to the SteeringHelm................................................................12Connection of the Hydraulic Hoses to the PowerSteering Pump.................................................14Connection of the Hydraulic Hoses to the SteeringCylinder............................................................15Electrical Connections to the Steering Pump. .17Filling Power Steering System with Engine NotRunning...........................................................19Filling Power Steering System with EngineRunning...........................................................21Routing Connections Through the Cowl..........22Fuel Hose Connection.....................................23

Wiring And Installation ......................................... 24Wire Color Code Abbreviations.......................24Installation Guidelines for DTS SystemComponents....................................................24Data Harness Pulling Procedure.....................24

Junction Box (If Equipped)...............................25Non-Mercury Marine Provided Ignition Switch.25Wiring Accessories..........................................26System Wiring Reference Points.....................26Battery Cable Size For Outboard Models........27Connecting 14 Pin Data Harness - SingleEngine..............................................................29Connecting 14 Pin Data Harness - Dual Engine.........................................................................30Installing DTS Command Module and Harness -Single Engine...................................................31Installing DTS Command Module and Harness -Dual Engine/Single Helm.................................34Battery Information..........................................35Connecting Battery Cables and DTS PowerHarness...........................................................36Connecting Fuel Tank And Speed Sensor .....39Switched 12V Accessory Connection..............41DTS Wiring - Single Engine.............................42DTS Wiring - Dual Engine................................44System Wiring Installation Checklist................45

Propeller Installation ........................................... 45Paddle Wheel Speed Sensor Installation (IfEquipped) ............................................................ 47

Parts Provided ................................................ 47Selecting Location .......................................... 47Transom Angle Requirements ........................ 48Installing Bracket ............................................ 48Routing the Cable ........................................... 49Installing and Removing the Paddle Wheel .... 50Wiring Connections ......................................... 50Template - Paddle Wheel Speed Sensor ....... 51

200/225/250/275 VERADO 4-STROKE

Page 2 / 51 90-10238051

Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

94 Anti-Corrosion Grease Propeller shaft splines 92-802867A1

95 2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A1

Notice to InstallerThis Product Requires Electronic Calibration Before Use.Installation of this product will require electronic calibration. This calibration must not beattempted by anyone other than the Original Equipment Manufacturer (OEM) or aMercury technician trained in Digital Throttle and Shift systems (DTS) at an authorizedMercury dealership. Improper installation and calibration of the DTS product will result ina system which is inoperable or unsafe for use.

Avoiding Loss of Throttle and Shift Control! WARNING

To avoid the possibility of serious injury or death from loss of boat control, do not spliceor probe into any wire insulation of the DTS system. Splicing or probing will damagethe wire insulation allowing water to enter the wiring. Water intrusion may lead to wiringfailure and loss of throttle and shift control.

Accessory Electric Fuel Pump/Fuel Line Primer BulbIMPORTANT: Do not install either an accessory electric fuel pump or a fuel line primerbulb into the fuel system of this engine.

Avoiding Fuel Flow RestrictionIMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.)may restrict the fuel flow. This may cause engine stalling at low speed, and/or a lean fuelcondition at high RPM that could cause engine damage.

Boat Horsepower Capacity! WARNING

Using an outboard that exceeds the maximum horsepower limit of a boat can: 1) causeloss of boat control 2) place too much weight at the transom altering the designedflotation characteristics of the boat or 3) cause the boat to break apart particularlyaround the transom area. Overpowering a boat can result in serious injury, death orboat damage.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 3 / 51

Do not overpower or overload your boat. Most boats will carry a required capacity plateindicating the maximum acceptable power and load as determined by the manufacturerfollowing certain federal guidelines. If in doubt, contact your dealer or the boatmanufacturer.

U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSON CAPACITY (POUNDS) XXXMAXIMUM WEIGHT CAPACITY XXX

ob00306

Selecting Accessories For Your OutboardGenuine Mercury Precision or Quicksilver Accessories have been specifically designedand tested for this outboardSome accessories not manufactured or sold by Mercury Marine are not designed to besafely used with this outboard or outboard operating system. Acquire and read theinstallation, operation, and maintenance manuals for all selected accessories.

Fuel TanksPortable Fuel Tank

Select a suitable location in the boat within the engine fuel line length limitations andsecure the tank in place.

Permanent Fuel TankPermanent fuel tanks should be installed in accordance with industry and federal safetystandards, which include recommendations applicable to grounding, anti-siphonprotection, ventilation, etc.

200/225/250/275 VERADO 4-STROKE

Page 4 / 51 90-10238051

Determining Recommended Outboard Mounting Height

(20 in.)

(21 in.)

(22 in.)

(23 in.)

(24 in.)

(25 in.)

(26 in.)

(19 in.)

10 20 30 40 50 60 70 80

66.0 cm

63.5 cm

60.9 cm

58.4 cm

56.0 cm

53.3 cm

50.8 cm

48.2 cm

e

a

c

d

b

b

e

f ob01470

a - The solid line is recommended to determine the outboard mounting height.b - The broken lines represent the extremes of known successful outboard

mounting height dimensions.c - The line may be preferred to determine outboard mounting height dimension,

if maximum speed is the only objective.d - The line may be preferred to determine outboard mounting height dimension

for dual outboard installation.e - Outboard mounting height (height from a point on the pedestal 48 mm

[1-7/8 in.] above center of top mounting hole to the bottom of the boattransom). For heights over 56.0 cm (22 in.), a propeller designed for surfacingoperation is usually preferred.

f - Maximum boat speed (m.p.h.) anticipated.

NOTICE• The static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE" mark on the

idle relief grommet (located at the rear of the outboard), when the outboard is fully tilted in/down. Ifwaterline is above "MAX STATIC WATERLINE" mark, adjust boat load forward or increase (raise)outboard mounting height to correctly place mark above waterline.

• Add 12.7 cm (5 in.) for XL models and 25.4 cm (10 in.) for XXL models to listed outboard mountingheight.

• The mounting height of the outboard must not exceed 63.5 cm (25 in.) for XL models and 76.2 cm(30 in.) for XXL models. Mounting the outboard higher may cause damage to the gearcasecomponents.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 5 / 51

Increasing the mounting height will usually:• Increase top speed• Increase boat stability• Cause propeller to break loose during planing or turning

Installing OutboardInstallation Specifications

a b

a

4241

a - Minimum transom openingb - Engine center line for dual engine - 66.0 cm (26 in.)

Minimum Transom Opening Single engine 99.0 cm (39 in.) Dual engine 165.0 cm (65 in.)

Maximum Outboard Mounting HeightThe mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models,76.2 cm (30 in.) for XL models and 88.9 cm (35 in.) for XXL models. Mounting the outboardhigher may cause damage to the gearcase components.

ob01312

200/225/250/275 VERADO 4-STROKE

Page 6 / 51 90-10238051

MAXIMUM STATIC WATERLINEThe static waterline, with boat at rest, must be below the "MAX STATIC WATERLINE"mark on the idle relief grommet (located at the rear of the outboard) when the outboardis fully tilted in/down. If waterline is above "MAX STATIC WATERLINE" mark, adjust boatload forward or increase (raise) outboard mounting height to correctly place mark abovewaterline.

MAX STATICWATERLINE

4224

Drilling Outboard Mounting HolesIMPORTANT: Before drilling any mounting holes, carefully read DeterminingRecommended Outboard Mounting Height. There is a 19 mm (0.75 in.) differencebetween the outboard mounting holes in the transom brackets.

! WARNINGAvoid possible serious injury or death. Do not, under any circumstances, allow the upperoutboard mounting bolts to be closer than 25.4 mm (1 in.) from the top of the boattransom. Never install the upper mounting bolts through shims.

1. Mark four mounting holes on the transom using the transom drilling fixture.

or69-1

a

a

b

ca - Drill guide holesb - Transom drilling fixture - not includedc - Transom centerline

Transom Drilling fixture 91-98234A2

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 7 / 51

2. Place masking tape directly onto the boat where the mounting holes will be drilled tohelp keep the fiberglass from chipping.

3973

3. Using the drill guide holes on the transom drilling fixture, drill four 13 mm (17/32 in.)holes perpendicular to and through the transom.

Lifting Outboard1. Remove top cowl and engine flywheel cover.2. Install lifting ring/flywheel puller to flywheel. Tighten bolts securely.3. Lift engine using engine lift with a minimum capacity of 450kg (1000 lb.).4. Avoid interference by placing the lower mounting bolts into the lower mounting slots

before placing outboard against the transom.

200/225/250/275 VERADO 4-STROKE

Page 8 / 51 90-10238051

5. Refer to Determining Recommended Outboard Mounting Height, and install outboardto the nearest recommended mounting height.

3731

a

b

a - Lifting eye b - Mounting bolts

Lifting Eye 91-895343T01

6. Fasten outboard with mounting hardware provided. Refer to Fastening Outboard.

Fastening Outboard1. Place lower mounting bolts into mounting slots before placing outboard on transom.2. Refer to Determining Recommended Outboard Mounting Height, and install outboard

to the nearest recommended mounting height.3. Fasten outboard with the stainless steel bolts, nylon insert locknuts and flat washers

as shown.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 9 / 51

! CAUTIONTo avoid loss of outboard, ensure that a minimum of two full threads of bolt extendbeyond locknut after tightening locknut. Ensure mounting nut is tightened againsttransom, not the shank of the mounting bolt.

a

bc

d

5552

e

a - Transom bolts (1/2 x 20) (4)b - Flat washers - outer (4)c - Nylon insert locknuts (4)

d - Flat washers - inner (4)e - Marine sealer - apply to shank of

bolts, not threads

Outboard Transom Mounting Hardware - Supplied with OutboardPart Number Part Name Description10-67755003 Transom bolt 1/2 x 20 x 5.50 in. long (3.25 in. thread)11-826711-17 Nylon insert locknut 1/2 x 20

12-28421 Washer - inner 0.516 in. ID x 1.50 in. OD12-895062 Washer - outer 0.551 in. ID x 1.06 in. OD

Available Transom Mounting BoltsPart Number Part Name Description10-814259 Transom bolt 1/2 x 20 x 4.00 in. long (2.25 in. thread)10-67755-1 Transom bolt 1/2 x 20 x 4.50 in. long (2.25 in. thread)10-67755-2 Transom bolt 1/2 x 20 x 6.50 in. long (2.75 in. thread)

200/225/250/275 VERADO 4-STROKE

Page 10 / 51 90-10238051

Power Steering InstallationPower Steering System

a

b

c

ob01457

a - Steering helmb - Steering cylinder on outboard

c - Power steering pump

Installation ProcedureNOTE: On some large/heavy dual outboard boats the steering forces generated inextreme maneuvers may create loads that exceed the pump's pressure capacity. If thehappens, the operator may feel intermittent periods of load feedback at the steeringwheel. The steering wheel may feel hard to turn for brief periods during these extrememaneuvers. If this happens and steering performance is deemed unacceptable for theapplication, a second (accessory) cylinder may be rigged. When using a second steeringcylinder the 40cc helm should be replaced with a 50cc helm.

SELECTING LOCATION FOR THE POWER STEERING PUMP

! CAUTIONTo ensure proper steering operation, hydraulic power steering system must beprotected from contamination. Make hydraulic connection in a clean work area. Routehoses with the protective shipping caps in place. Remove protective shipping cap fromhose and component fitting as each connection is made.

1. Select a mounting location (floor or side of internal bulkhead) for the installation of thepower steering pump that meets the following requirements

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 11 / 51

• To reduce noise on aluminum or metal hulls, isolate steering hoses from hull withsuitable non-abrasive hangers.

• Steering hoses from steering wheel helm must be free of twists or stress. Gentlysecure hose bundle together with a cable tie, located approximately 25.4 cm(10 in.) from the steering wheel helm.

• Do not mount pump on an angle greater then 15° from vertical position.• The pump electrical wiring must be within reach of the auxiliary battery.• Pump should be mounted in an area that allows sound enclosure, cover removal,

and easy access to the fill cap.• Install pump in an area where bilge water will not contaminate the pump.• To reduce transmitted noise, mount pump on wood or fiberglass surface. Avoid

mounting pump on aluminum or steel surfaces.REQUIRED MOUNTING CLEARANCES FOR THE POWER STEERING PUMP

a c

ob01458

bd

a - 215 mm (8 1/2 in.)b - 310 mm (12 7/32 in.) to top cover (not shown)c - 285 mm (11 1/4 in.)d - 432 mm (17 in.) clearance required for cover removal

INSTALLING POWER STEERING PUMP1. The power steering pump can be mounted two ways:

• On a side of the internal bulkhead• Mounted on the floor

200/225/250/275 VERADO 4-STROKE

Page 12 / 51 90-10238051

2. Mount the power steering pump at the selected location, using appropriate fasteninghardware suitable for the type of material and thickness of the mounting surface.

ob01459

a

a a

a

b

b

Mounted on internal bulkhead Mounted on floora - Lag screws or thru-bolts (3 or 4)b - Mounting hardware

Connection of the Hydraulic Hoses to the Steering HelmNOTE: Hoses must be routed up through steering helm opening in dash and secured tohelm fittings prior to mounting the steering helm.1. Place the steering hoses through one backing plate on the internal side of the

dashboard. Route the steering hoses through the drilled opening, and place therequired amount of backing plates on the hoses on the external side of the dashboard.

NOTE: The number of backing plates varies depending on helm displacement.

4027

a

a - Backing plates

2. Remove and discard the shipping caps from ends of the four fittings on the steeringhelm. Ensure the O-ring seals did not lift off with the shipping caps.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 13 / 51

3. Ensure O-ring seals are in place on end of steering helm fittings.

a

b

ob01460

a - O-ring seals (4) b - Plug - not used

4. Make the hose connections to the steering helm as shown. Use a thin wrench andhold the helm fittings from turning while tightening hoses. Do not over-tighten the hoseconnections.

a

P T

ob01461

R S

TAR

L PO

RT

b

c

d e

a - Thin wrenchb - Helm hex fitting wrench size (P & T) - 19 mm (3/4 in.)c - Helm hex fitting wrench size (R & L) - 16 mm (5/8 in.)d - Hydraulic hose hex fitting wrench size (P & T) - 21 mm (13/16 in.)e - Hydraulic hose hex fitting wrench size (R STAR & L PORT) - 18 mm

(11/16 in.)

Helm Fitting ID Mark Hose ID Mark DescriptionP P Pressure from pump to helmT T Tank low pressure return to pump

200/225/250/275 VERADO 4-STROKE

Page 14 / 51 90-10238051

Helm Fitting ID Mark Hose ID Mark DescriptionR R-STAR Hose connects to starboard side of steering cylinderL L-PORT Hose connects to port side of steering cylinder

Connection of the Hydraulic Hoses to the Power Steering Pump1. Remove and discard the yellow protector cap from end of tank low pressure fitting.2. Connect the low pressure hydraulic hose from the steering helm to the low pressure

fitting on the pump reservoir as shown. Fasten hose to fitting with constant tensionspring clamp.

b

c

ob01462

a

a - Yellow protector cap (remove and discard)b - Low pressure hydraulic hose from steering helmc - Clamp

3. Ensure that O-ring seal is on end of hose.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 15 / 51

4. Connect the high pressure hydraulic hose from the steering helm to the pump asshown.

a

ob01463

b

a - O-ring b - High pressure hydraulic steeringhose

Connection of the Hydraulic Hoses to the Steering Cylinder1. Route the hydraulic hoses to the outboard steering cylinder. Bulkhead fittings are

available if an opening does not exist in the engine well.

a b

ob01464

a - Bulkhead fitting - bulkhead thickness up to 1.9 cm (0.75 in.) (22-892517)b - Bulkhead fitting - bulkhead thickness up to 7.62 cm (3 in.) (22-892518)

NOTE: The 90° hose fittings on the steering cylinder can be rotated to align with hoserouting. Straight hose fittings (22-892519) are also available.

200/225/250/275 VERADO 4-STROKE

Page 16 / 51 90-10238051

2. Position the 90° hose fittings to the desired direction. Loosen fastening nuts in orderto rotate. Position fittings and re-tighten fastening nuts.

b

c

ob01465

a

a - Position fittingsb - 90° fitting

c - Straight fitting

3. Remove and discard the shipping caps from the two fittings on the steering cylinder.Ensure O-ring seals did not lift off with shipping caps.

4. Ensure O-ring seals are in place on end of each fitting.

a a

ob01466

a - O-rings

5. Make the hydraulic steering hose connections to the steering cylinder as shown.

ob01467

L PORT

R STAR

a

b

a - Port fitting (L PORT) b - Starboard fitting (R STAR)

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 17 / 51

Electrical Connections to the Steering PumpNOTE: For single engine installation, the power steering pump battery cables should beconnected directly to the outboard starting battery.

+

- a

b

c d

ef

g

hi

jk

4250

b

Single Engine Applicationa - Engineb - Battery cablec - DTS power harnessd - Batterye - Power steering fuse - 90 Ampf - Power steering pump 12V positive

harness

g - Power steering pumph - Driver modulei - Power steering pump ground

harnessj - Power steering signal harnessk - Engine signal harness

200/225/250/275 VERADO 4-STROKE

Page 18 / 51 90-10238051

NOTE: On multiple installations, the Automatic Battery Switch (ABS) (87-895091K01),must be used to connect all outboard starting batteries to the power steering pump. TheABS allows battery voltage to be drawn from the starting battery with the highest state ofcharge.

+

-

+

-

a

b

c

d

e

fg

h i

j

m

l

m

4154

k

k

Dual Engine Applicationa - Port engineb - Starboard enginec - Port batteryd - Starboard batterye - Automatic Power Switch (APS)f - Power Steering Pumpg - Power steering pump 12V positive

harness

h - Power steering pump groundharness

i - Driver modulej - Dual engine power steering adaptork - DTS power harnessl - Power steering signal harnessm -Engine signal harness

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 19 / 51

1. Make electrical connections to the pump as shown.

+ +

- -

R E D

a

b

c e

BLK

ob01468 d

a - Power steering pumpb - Auxiliary battery (preferred)c - Diode harness

d - Battery leadse - 3 pin connector from engine

Filling Power Steering System with Engine Not RunningUse SAE 0W-30 Full Synthetic Power Steering Fluid in the power steering system. In anemergency, if recommended power steering fluid is not available, the use of any fullsynthetic engine oil can be temporarily used. The power steering fluid should then bedrained and replaced with SAE 0W-30 Full Synthetic Power Steering Fluid as soon aspossible, to avoid loss of performance in power steering system.

Fluid Type Capacity Mercury Part NumberSAE 0W-30 Full Synthetic PowerSteering Fluid

1 - 2 liters (1 - 2 quarts) depending on lengthof steering hoses 92-858002K01

1. Disconnect power steering signal harness from engine signal harness.2. Connect the Power Steering Primer Module Kit to the power steering pump and 12

volt positive power source as shown.

+

-

a

b c

R E D

BLK

ob01469

d

a - Power steering pumpb - Primary battery

c - Battery leadsd - Power steering primer module

Power Steering Primer Module Kit 91-895040K01

3. Remove the filler cap and filter from the power steering pump.

200/225/250/275 VERADO 4-STROKE

Page 20 / 51 90-10238051

4. Fill the pump tank with recommended power steering fluid.

4101

a

bc

a - Fill capb - Filter

c - Full level

IMPORTANT: The power steering module primer has two switches, "POWER" - "ON"and "OFF", and "PUMP" - "ON" and "OFF". To power up and activate the power steeringpump, there are two steps: 1) Turn the "POWER" switch to the "ON" position to powerup pump, wait for two seconds, then, 2) Turn the "PUMP" switch to the "ON" position toactivate pump.IMPORTANT: Do not run pump out of fluid. If pump draws air during bleeding, theresulting re-bleeding will take two to three times longer than initial bleeding.5. Power up and activate the pump until fluid drops halfway. Turn off both switches on

the power steering primer module and refill the pump tank. Repeat this operation untilpump tank stays full.

6. Power up and activate the pump while slowly turning the steering wheel towards thefull lock position in one direction. Carefully monitor the fluid level until fluid dropshalfway, stop turning the steering wheel and refill the pump tank. Repeat thisoperation turning the steering wheel from full lock to full lock 10 times until pump tankstays full.

7. For bleeding any air left in the steering system, power up and activate the pump. Turnthe steering wheel in one direction until the full lock position is met.

8. Attach an 8 mm I.D. (5/16 in. I.D.) transparent bleed hose to the bleed valve on theend of the steering cylinder that the engine is pointing to. Route bleed hose into pumptank (do not bleed power steering fluid into a different container, this will only bepumping fluid out of the system that was just filled up).

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 21 / 51

9. Open bleed valve to release any remaining air in the power steering system. Allowadequate time, depending on length of power steering hose, for air to escape fromsystem. Tighten bleed valve securely and remove bleed hose.

a b

3640

a - Bleed hose b - Bleed valve in steering cylinder

10. Turn the steering wheel to opposite full lock position, and repeat steps 8 and 9.11. Replace the filter and fill cap on the power steering pump.12. If desired, the power steering system can be rechecked after sitting overnight to

remove any air that may possibly be left in the system. Repeat steps for bleedingsteering system, preceding.

13. Turn off both switches, remove the power steering primer module and reconnect thepower steering signal harness from the engine to the pump.

Filling Power Steering System with Engine Running1. Remove the filler cap and filter from the power steering pump.2. Fill the pump tank with recommended power steering fluid.

4101

a

bc

a - Capb - Filter

c - Full level

3. Start and run the engine until the steering pump fluid drops halfway. Turn off theengine and refill the pump. Repeat this operation until pump stays full.

4. Start and run the engine while slowly turning the steering wheel towards the full lockposition in one direction. Carefully monitor the fluid level until fluid drops halfway. Stopturning wheel, turn off engine, and refill the pump tank. Repeat this operation turningthe steering wheel to full lock to full lock 10 times until pump tank stays full.

200/225/250/275 VERADO 4-STROKE

Page 22 / 51 90-10238051

5. For bleeding any air left in the steering system, start and run the engine, and turn thesteering wheel in one direction until the full lock position is met.

6. Attach an 8 mm (5/16 in.) I.D. transparent bleed hose to the bleed valve on the endof the steering cylinder that the engine is pointing to. Route bleed hose into pumptank (do not bleed power steering fluid into a different container, as this will only bepumping fluid out of the system that was just filled).

7. Open bleed valve to release any remaining air in the power steering system. Allowadequate time, depending on length of power steering hose, for air to escape fromsystem. Tighten bleed valve securely and remove bleed hose.

a b

3640

a - Bleed hose b - Bleed valve in steering cylinder

8. Turn the steering wheel to opposite full lock position, and repeat procedure forbleeding steering system.

9. Replace the filter and filler cap on the power steering pump.10. If desired, the power steering system can be rechecked after sitting overnight to

remove any air that may possibly be left in the system. Repeat steps for bleedingsteering system, preceding.

Routing Connections Through the CowlIMPORTANT: Ensure that sufficient excess exists in the wiring harness and batterycables routed between the cowl fitting and the engine attachment point to relieve stressand prevent hoses from being kinked or pinched. Ensure that excess exists in all hosesand cables in full left and right turns and full tilt position.NOTE: Mercury Marine suggests routing the wiring, cables and fuel hose through arigging hose or flexible sleeve from the engine to the boat's gunnel or motor well. Followthe installation instructions included with the Rigging Hose or Flexible Sleeve Kit.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 23 / 51

1. Pull out the grommet fitting from the front cowl opening. Route the wiring harnesses,battery cables, and fuel hose through the correct openings in the rubber grommet asshown.

F H

B AWTB

3723

cb

a

fe

h

d

g

a - Rubber grommetb - Fuel hosec - 14 pin data harnessd - DTS power harness, vessel sensor harness, power steering pump harnesse - Large diameter battery cablesf - Small diameter battery cablesg - Grommet fittingh - Front cowl opening

2. Insert rubber grommet into fitting and secure fitting in front cowl opening.

Fuel Hose ConnectionFUEL HOSE SIZE

IMPORTANT: Fuel line inside diameter (I.D.) must be 10 mm (3/8 in.) with separate fuelline/fuel tank pickup for each engine.Fasten remote fuel hose to fitting with hose clamp.

a b

3730

F E

a - Remote fuel hose b - Hose clamp

200/225/250/275 VERADO 4-STROKE

Page 24 / 51 90-10238051

Wiring And InstallationWire Color Code Abbreviations

Wire Color AbbreviationsBLK Black

BLU BlueBRN Brown GRY GrayGRN Green ORN or ORG OrangePNK Pink PPL or PUR PurpleRED Red TAN TanWHT White YEL YellowLT or LIT Light DK or DRK Dark

Installation Guidelines for DTS System Components

! WARNINGTo avoid the possibility of serious injury or death from loss of boat control, do not spliceor probe into any wire insulation of the DTS system. Splicing or probing will damagethe wire insulation allowing water to enter the wiring. Water intrusion may lead to wiringfailure and loss of throttle and shift control.

DATA HARNESS

! WARNINGTo avoid the possibility of serious injury or death from loss on boat control, do not pullon cable connectors when pulling cable into boat. Observe correct pulling procedure.Pulling on connectors can loosen terminals resulting in open or poor electricalconnections. Open or poor electrical connections may result in loss of throttle and shiftcontrol.

CONNECTORSIMPORTANT: Connectors should never have to be forced into the receptacle. Ensurethat connectors are free of any lubricant or dielectric grease before installation. When theconnector is properly aligned, it will only take a small amount of pressure to insert it intothe receptacle. Rotate the locking collar to secure the electrical connection.NOTE: Connect only one data harness of the required length between the engine andhelm. If a data harness is too short, do not connect multiple harnesses together to makeup the required length. For installations requiring a data harness length longer than12.2 m (40 ft.), contact Mercury Marine for more information.

Data Harness Pulling ProcedureIMPORTANT: Do not route data harness near engine ignition components (coils, sparkplug leads, and spark plugs), high power VHF coax or radios. An electrical field generatedfrom these components could cause interference with data transmission.IMPORTANT: Do not route data harness near sharp edges, hot surfaces or moving parts.Fasten cables away from any sharp edges, fasteners or objects that could wear into theharness.IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be7.6 cm (3 in.) for the final wiring installation.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 25 / 51

1. Inspect the routing path to make sure surfaces are free of any sharp edges or burrsthat could cut the harness.

2. Install cable pulling tool to data harness.3. Secure pulling tool with 2 cable ties.IMPORTANT: The cables ties must be tight to prevent any slipping during installation.

3836

Data Cable Puller 91-888462A1

IMPORTANT: Carefully inspect data harness pins to ensure all pins are securelyfastened to data harness connector end following installation.NOTE: Data harness should be secured with mounting clips or cable ties along the routingpath.

Junction Box (If Equipped)• Although the junction box connections are watertight, it is recommended that the

junction box be mounted in an area that stays relatively dry.• Mount in an area where the wiring connection will not get stepped on or disturbed.• Mount in an area that is accessible for troubleshooting and servicing the system.• Ensure the DTS command module harness will reach all the connection points.• Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.• Seal all unused connections with weather caps.

a

d

ob01481

b c

e

a - Clampb - Weather cap (859318T 2)c - Junction box

d - 25.4 cm (10 in.)e - DTS Command Module harness

Non-Mercury Marine Provided Ignition Switch

! CAUTIONPrevent unexpected engine start-up. Non-Mercury Marine ignition switches may allowsufficient current leakage to cause engine to start unexpectedly.

200/225/250/275 VERADO 4-STROKE

Page 26 / 51 90-10238051

IMPORTANT: Correct ignition key switch must be used. If a non-Mercury Marine ignitionkey switch is being used, make sure that the ignition switch being used meets therequirement listed.IMPORTANT: Current leakage exceeding 5 mA at 12 volts could cause engine to startunexpectedly.• Ignition key switch must pass ingress protection testing per IEC IP66 specification

minimum. Switches that do not pass this specification could leak current.• Switches must contain an emergency stop circuit.

a

B L K / Y E L

B L K

P P L

Y E L / R E D R E D

P P L B L K / Y E L B L K

P P L

Y E L / R E D R E D

P P L

c d e f g

3641 / WHT h

/ WHT

b

4 Position Key Switcha - Connector - Packard Metripack

150 Series Sealed™ (6 pin)b - Ignition switchc - Crankd - + 12V

e - Lanyard stopf - Groundg - Runh - Accessory - 4 position key switch

Wiring AccessoriesNOTE: Refer to Mercury Precision Parts Accessories Guide.

System Wiring Reference PointsFEATURES

• DTS power harness - Provides 12V power to the DTS system. Requires connectionto the starting battery. If starting battery is located at the helm, DTS power harnessaccessory kit is required to minimize voltage drop. Use cable ties to secure powerharness leads to battery cables, beginning within 15 cm (6 in.) of battery posts andcontinuing along the entire length of the harness.

• Battery cables - Connect to the starting battery.• Vessel sensor harness - This harness connects to the main fuel tank sensor, auxiliary

fuel tank and the paddle wheel speed/temperature sensor, if equipped.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 27 / 51

• 14 pin data harness - Connects between the command module harness and engine.

a

3675

b c

d

e

f

a - 14 pin data harnessb - Power steering pump harnessc - Vessel sensor harnessd - Battery cablese - DTS power harnessf - 5 Amp fuse

Battery Cable Size For Outboard ModelsIMPORTANT: Only use copper battery cables. Do not use aluminum cables for anyoutboard marine installations.• If longer battery cables are required, the wire gauge size must increase. See chart

following for correct wire gauge size.• DTS L models are equipped with 3.7 m (12 ft.) cables. DTS XL and XXL models are

not shipped with battery cables.

a

b or70

a - Wire gauge size b - Battery cable length

200/225/250/275 VERADO 4-STROKE

Page 28 / 51 90-10238051

Copper Battery Cable Wire Gauge SizeWire Gauge Size Number SAE

Models 6-25 hp 30-115 hp (except OptiMax) 125-250 hp (except OptiMax) OptiMax/Verado

Cable Length

2.4 m (8 ft.) 81. 61. - -

2.7 m (9 ft.) 6 4 - -

3.0 m (10 ft.) 6 4 61. -

3.4 m (11 ft.) 6 4 4 -

3.7 m (12 ft.) 6 4 4 41.

4.0 m (13 ft.) 6 2 4 24.3 m (14 ft.) 4 2 4 24.6 m (15 ft.) 4 2 4 24.9 m (16 ft.) 4 2 2 25.2 m (17 ft.) 4 2 2 25.5 m (18 ft.) 4 2 2 25.8 m (19 ft.) 4 2 2 26.1 m (20 ft) 4 2 2 26.4 m (21 ft.) 2 1 2 16.7 m (22 ft.) 2 1 2 17.0 m (23 ft.) 2 1 2 17.3 m (24 ft.) 2 1 2 17.6 m (25 ft.) 2 1 2 17.9 m (26 ft.) 2 1/0 1 1/08.2 m (27 ft.) 2 1/0 1 1/08.5 m (28 ft.) 2 1/0 1 1/08.8 m (29 ft.) 2 1/0 1 1/09.1 m (30 ft.) 2 1/0 1 1/09.4 m (31 ft.) 2 1/0 1 1/09.8 m (32 ft.) 2 1/0 1 1/010.1 m (33 ft.) 2 2/0 1/0 2/010.4 m (34 ft.) 2 2/0 1/0 2/010.7 m (35 ft.) 1 2/0 1/0 2/011.0 m (36 ft.) 1 2/0 1/0 2/011.3 m (37 ft.) 1 2/0 1/0 2/011.6 m (38 ft.) 1 2/0 1/0 2/011.9 m (39 ft.) 1 2/0 1/0 2/012.2 m (40 ft.) 1 2/0 1/0 2/0

1. Standard (original) cable length and wire gauge size.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 29 / 51

Connecting 14 Pin Data Harness - Single EngineSINGLE HELM

IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm(3 in.).

ab

3619

a - 14 pin data harness b - Clamp or cable tie

DUAL HELM

3682

a

b

c

d

e

a - 14 pin data harnessb - Helm 2 (upper helm)c - Helm 1 (lower helm)

d - Dual helm adapter (Y harness)e - Clamp or cable tie

200/225/250/275 VERADO 4-STROKE

Page 30 / 51 90-10238051

Connecting 14 Pin Data Harness - Dual EngineSINGLE HELM

IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm(3 in.).

3977

a

b

a - 14 pin data harness b - Clamp or cable tie

DUAL HELM

3978

a

b

c

d

e

c

a - Helm 2 (upper helm)b - Helm 1 (lower helm)c - 14 pin data harness

d - Dual helm adapter (Y harness)e - Clamp or cable tie

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 31 / 51

Installing DTS Command Module and Harness - Single EngineHARNESS INSTALLATION

• Locate a routing path for the harness connections so they reach their installationpoints.

• Inspect the routing path to make sure surfaces are free of any sharp edges or burrsthat could cut the harness.

• Fasten and support the harness with clamps or cable ties along the routing path.• Make sure all connections are tight and seal all unused connectors with weather caps.

3622

a

b

Single Helm Applicationa - DTS command module harness b - Clamp or cable tie

200/225/250/275 VERADO 4-STROKE

Page 32 / 51 90-10238051

NOTE: For dual helm application - Remove CAN 1 and CAN 2 terminator resistors fromhelm 1 (helm closest to the engine), and seal connectors with weather caps.

3677

a

c

c

b

d

d

e f

g

h

TerminatorCAN 1

TerminatorCAN 2

Dual Helm Applicationa - Helm 2 (upper helm)b - Helm 1 (lower helm)c - DTS command module harnessd - Clamp or cable tie

e - CAN 1 connectorf - CAN 2 connectorg - Weather capsh - Terminator resistors, blue (CAN1 &

CAN2)

MODULE INSTALLATION• Although the Command Module connection is watertight, it is recommended that it be

mounted in an area that stays relatively dry.• Mount in an area where the wiring connection will not get stepped on or disturbed.• Mount in an area that is accessible for troubleshooting and servicing the system.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 33 / 51

• Ensure the wiring harness connected to the command module will reach all theconnection points.

a

b

3625

Single Helm Applicationa - DTS command module b - Clamp or cable tie

3678

a

b

c d

e

f

Dual Helm Applicationa - Helm 2b - Helm 1c - DTS command module

d - Clamp or cable tiee - Terminator resistors, blue (CAN1 &

CAN2)f - Weather caps

200/225/250/275 VERADO 4-STROKE

Page 34 / 51 90-10238051

Installing DTS Command Module and Harness - Dual Engine/Single HelmHARNESS INSTALLATION

• Locate a routing path for the harness connections so they reach their installationpoints.

• Inspect the routing path to make sure surfaces are free of any sharp edges or burrsthat could cut the harness.

• Fasten and support the harness with clamps or cable ties along the routing path.• Make sure all connections are tight and seal all unused connectors with weather caps.

Term

inat

or

CAN

1Te

rmin

ator

C

AN 1

Terminator CAN 2

Terminator CAN 2

a

b

d3689

c

c

e

a - CAN link harnessb - CAN 2 Terminator resistors - do

not removec - CAN 1 connectors

d - Clamp or cable tiee - DTS command module harness

MODULE INSTALLATION• Although the Command Module connection is watertight, it is recommended that it be

mounted in an area that stays relatively dry.• Mount in an area where the wiring connection will not get stepped on or disturbed.• Mount in an area that is accessible for troubleshooting and servicing the system.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 35 / 51

• Ensure the wiring harness connected to the command module will reach all theconnection points.

3691

ab

c

c

a - DTS command moduleb - Clamp or cable tie

c - CAN link harness

Battery Information

! CAUTIONHex nuts must be used to secure battery leads to battery posts to avoid loss of electricalpower.

• Do not use deep cycle batteries. Engines must use a marine starting battery with 1000MCA, 800 CCA or 180 Ah.

• When connecting engine battery, hex nuts must be used to secure battery leads tobattery posts. Torque nuts to specification.

Description Nm lb. in. lb. ft.Hex nuts 13.5 120

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manualfor size requirements.

200/225/250/275 VERADO 4-STROKE

Page 36 / 51 90-10238051

Decal needs to be placed on or near battery box for future service reference. One5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metrichex nuts are not supplied.

Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.

NOTICE - DTS & Optimax Engines

37-895387

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.

DO NOT USE WING NUTS.

DO NOT USE DEEP CYCLE BATTERIES!

13.5Nm (120 lbs. in.)

DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.rating.

3486

Connecting Battery Cables and DTS Power Harness

! CAUTIONTo avoid the possibility of loss of electrical power due to the DTS power harnessconnection being pulled off battery, fasten the DTS power harness to one of the batterycables near the battery with cable tie.

• Install DTS power harness directly to the starting battery only.• Do not extend lead length of harness.• See accessory manual for optional lead connection kit.

3711

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 37 / 51

SINGLE ENGINE - BATTERY AT STERN

c

a

b

d

3679

a - Batteryb - Black sleeve (negative)

c - Red sleeve (positive)d - DTS power harness (provided)

SINGLE ENGINE - BATTERY AT HELM

a

b

e

3699

dc

f

g

h

a - 14 pin data harnessb - DTS command module harnessc - Junction boxd - DTS power harness (optional)

e - Red sleeve (Positive)f - Black sleeve (Negative)g - Vessel sensor harnessh - Weather caps

200/225/250/275 VERADO 4-STROKE

Page 38 / 51 90-10238051

DUAL ENGINE - BATTERY AT STERN

c

b

c

a b

a

3680

d d

e

f

g

a - Red sleeve (positive)b - Black sleeve (negative)c - Batteryd - DTS power harness (provided)

e - Ground cablef - Data cableg - Vessel sensor harness

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 39 / 51

DUAL ENGINE - BATTERY AT HELM

3701

a ab bc c

d

e

f fg

h

a - Black sleeve (negative)b - Red sleeve (positive)c - DTS power harness (optional)d - DTS command module harness

e - Junction box weather capsf - 14 pin data harnessg - Ground cableh - Vessel sensor harness

Connecting Fuel Tank And Speed SensorIMPORTANT: Do not connect the blk/orn wire (if equipped) to the fuel tank sensor whenthere is an engine battery ground strap connected to the fuel tank or sender assembly.If not used, plug the unused open bullet connector with rubber plug.IMPORTANT: If fuel tank is plastic and fuel sensor mounting plate is not connected tobattery ground, connect blk/orn wire (if equipped) to fuel sender mounting plate.

200/225/250/275 VERADO 4-STROKE

Page 40 / 51 90-10238051

IMPORTANT: Metal fuel tanks must be grounded to hull or battery ground in accordanceto coast guard regulations.

BLK

BLU

WH

T

YEL

BLK/

OR

G

PUR

/YEL

GR

Y/BL

U

TAN

/OR

G BLK/

OR

G

LT.B

LU/B

LK

PNK/BLK

BLK/ORG

b

c

de

a

5759

a - Paddle wheel kitb - Vessel harnessc - Black/orange wire connection, if

equipped

d - Fuel tanke - To second fuel tank

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 41 / 51

Switched 12V Accessory Connection

+ - ob01495

PUR

RED

a

b

cd

e

f

gh

a - Batteryb - Fuse - 40 Ampc - Power harness with 40 Amp fused - Switched 12V

e - Complete kitf - Terminal blockg - Accessory power relayh - DTS Command Module harness

200/225/250/275 VERADO 4-STROKE

Page 42 / 51 90-10238051

DTS Wiring - Single EnginePANEL CONTROL

a b

c

3718

WH

ITE

BLU

E

BLK/ORGPUR/YELGRN/YELGRN/ORGGRN/RED

BLK/

YEL

BLK/

YEL

BLK

BLK

OFF ON

e

f

g

h

ij

d

-+

a - Start/stop switch (optional)b - SmartCraft System View (optional)c - SmartCraft Link Gauge (optional)d - GPS connectione - Displace harness

f - Cable adaptor (male to female)g - Weather capsh - Junction box (optional)i - Accessory power relay (optional)j - Foot throttle (optional)

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 43 / 51

CONSOLE CONTROL

a b

c

3717

WH

ITE

BLU

E

BLK/ORGPUR/YELGRN/YELGRN/ORGGRN/RED

BLK/

YEL

BLK/

YEL

BLK

BLK

OFF ON

d

e

f

g

h

ij

-+

a - Start/stop switch (optional)b - SmartCraft System View (optional)c - SmartCraft Link Gauge (optional)d - GPS connectione - Display harness

f - Cable adaptor (male to female)g - Weather capsh - Junction boxi - Accessory power relay (optional)j - Foot throttle (optional)

200/225/250/275 VERADO 4-STROKE

Page 44 / 51 90-10238051

DTS Wiring - Dual EngineCONSOLE CONTROL

+

3309

a

e

k

i

l

j

mn

o

c

p

g

ib

d

h

l

j

q

i

d

e

b

c

rs

ff

g

a - To port engineb - Terminator resistorc - DTS Command Moduled - Junction box connection (optional)e - Connector - Zero Effort controlsf - Horng - Accessory power relay (optional)h - DTS Command Module harnessi - Clampj - Connector - stop/start switch

(optional)

k - Remote control connectionsl - Key switchm -Remote controln - To port engineo - Lanyard stop switchp - To starboard engineq - System View (optional)r - To starboard engines - CAN link harness

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 45 / 51

System Wiring Installation ChecklistDATA CABLE

Verify the data harness is not routed near sharp edges, hot surfaces or moving parts.Verify data harness is not routed near ignition components (coils, spark plug leads,and spark plugs), high power VHF coax or radios.

JUNCTION BOX (IF EQUIPPED)Verify the data harness is not routed near sharp edges, hot surfaces or moving parts.Ensure the harness connections are fastened within 25.4 cm (10 in.).Verify that all unused receptacles are covered with a weather cap.

NON-MERCURY MARINE SUPPLIED IGNITION KEY SWITCHIf a non-Mercury Marine ignition key is used, verify that it passes the ingress protectiontesting per IEC IP66 specification minimum. Ignition switches must pass thisspecification.

ELECTRONIC REMOTE CONTROLEnsure Electronic Remote Control (ERC) connections are completed following ERCinstallation instructions prior to engine operation.

DTS COMMAND MODULE HARNESSVerify that all connectors are properly inserted and locked in their receptacle (remotecontrol, key switch, command module, lanyard stop switch and junction box, ifequipped).Verify that while moving the remote control handle (full forward and full reverse) theharness has unobstructed movement (moves freely).Verify that the lanyard stop switch is wired into the system correctly.Verify that the harness is fastened along the routing path.Verify that all unused connectors have weather caps to prevent corrosion.

BATTERYVerify that wing nuts have been replaced with hex nuts, provided.Verify that all engine battery cables are connected to the correct terminals.Verify that the DTS power harness leads are connected to the starting battery andsecured with locknuts.Ensure the 5 Amp fuse for the DTS power harness is accessible.

LANYARD STOP SWITCHVerify that the switch is installed.Verify that the switch is connected to the DTS command module harness.

Propeller Installation! WARNING

When installing or removing propeller, ensure the remote control is in neutral positionand the key switch is "OFF". Place a block of wood between the anti-cavitation plateand propeller to prevent accidental starting and to protect hands from propeller bladeswhile removing or installing nut.

1. To aid in future removal of the propeller, liberally coat the propeller shaft splines withone of the following Mercury/Quicksilver products:

200/225/250/275 VERADO 4-STROKE

Page 46 / 51 90-10238051

Tube Ref No. Description Where Used Part No.

94 Anti-Corrosion Grease Propeller shaft splines 92-802867A1

952-4-C Marine Lubricant withTeflon Propeller shaft splines 92-802859A1

2. Flo-Torq II Drive Propellers - Install forward thrust hub, replaceable drive sleeve,propeller, thrust hub, propeller nut retainer, and propeller nut onto the shaft.

b ca

d

fe

ob00421

a - Propeller nutb - Propeller nut retainerc - Thrust hub

d - Propellere - Replaceable drive sleevef - Forward thrust hub

3. Place a block of wood between gearcase and propeller and torque nut to specification.

Description Nm lb. in. lb. ft.Nut 75 55

4. Secure propeller nut by bending three of the tabs into the thrust hub grooves.

ob00422

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 47 / 51

Paddle Wheel Speed Sensor Installation (If Equipped)Parts Provided

A B C D

a

b c

d e

f g

h

i

i

j ob01505

a - Spare pin yokeb - Wire retainerc - Connectord - Brackete - Paddle wheel

f - Flat washer (2)g - #10 - 19 mm (3/4 in.) screw (4)h - Cable capi - #6 - 12 mm (1/2 in.) screw (4)j - Clamp (2)

Selecting LocationSingle engine installation - Mount paddle wheel on the transom where the propeller bladeis rotating downward. Usually the right (starboard) side to minimize cavitation. If feasible,mount at least 50 mm (2 in.) beyond the swing radius of the propeller.Dual engine installation - Mount the paddle wheel between the engines as close to thecenter line (keel) of the boat as possible. On slower, heavier displacement boats,however, positioning it farther from the keel is acceptable.NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes or outletsfor live wells or any protrusion that may cause turbulence or cavitation.

a

ob01506

a - 50 mm (2 in.)

200/225/250/275 VERADO 4-STROKE

Page 48 / 51 90-10238051

Transom Angle RequirementsStandard 13° to 20° transoms - No special adjustment required.

a b

ob01507

a - 13° transom angle b - 20° transom angle

Stepped or undercut transom with 3 angles - A small shim of tapered plastic, metal orwood must be fabricated and installed as shown. Mount the paddle wheel on the step forbest performance.

a

ob01508

a - Shim

Installing Bracket1. Cut out the template. At the location selected, tape the template to the transom. Make

sure the black dotted line on the template is aligned with the transom bottom edge,as shown.

NOTE: The mounting template provided is located on the last page of this instructionsheet.2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on

the template. To prevent drilling too deeply, wrap masking tape around the drill bit22 mm (7/8 in.) from the point end of drill bit.

NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drillingabout 15 mm (1/16 in.) deep to prevent surface cracks.3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to

the two #10 screws provided. Using the washer provided, attach and tighten thebracket to the hull making sure the bracket is flush with the underside of the hull.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 49 / 51

4. Fill any gap between the housing and the transom with a caulking material, as shown.Using a putty knife, smooth the surface to ensure proper water flow.

b

c d

e

ob01509

a

a - Templateb - 50 mm (2 in.)c - #10 screw

d - Flat washer (2)e - Caulking

Routing the CableDRILLING HOLE THROUGH TRANSOM (OPTIONAL)

1. Select a transom location for the hole above the water line that does not interfere withother cables and controls.

2. Drill a 15 mm (5/8 in.) diameter hole.3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or

a comparable marine sealer after the cable has been routed through.NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. Thehole for the second clamp should be positioned halfway between the first clamp and thecap covering the transom hole drilled for the cable.4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm

(1/2 in.) deep.5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads,

install the cable clamps and feed the cable through cable cap.

200/225/250/275 VERADO 4-STROKE

Page 50 / 51 90-10238051

WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL)Route the cable over the transom or through a drain hole that is above the water line.

ob01510

a

b

c

d

e

a - Splash well drain holeb - Cable capc - Cable clampd - Paddle wheel assemblye - Distance between first cable clamp and top of paddle wheel - 25.4 mm

(1.0 in.)

Installing and Removing the Paddle WheelInstallation - Slide the pins into the slots in the bracket and snap the tabs into place.Removal - squeeze open (unlock) the tabs and pull on the paddle wheel.

a

b ob01511

a - Tabs b - Pins

Wiring ConnectionsIMPORTANT: Before making wire connections, make sure wires are routed through thetransom.

200/225/250/275 VERADO 4-STROKE

90-10238051 Page 51 / 51

NOTE: Wires can only be pushed into the connector one way. Align the wire terminal withthe tabs inside the connector. Have the wiring routed through the transom. Push eachwire terminal into its respective location in the connector. Push wire in until they snap intoplace. Secure wires into connector with the wire retainer.

A A B B

C C D D

A A B B

C C D D

a b b

W H T Y E L B L U B L K

ob01512

a - Connector b - Wire retainer

Template - Paddle Wheel Speed Sensor

a

b

ob01513

a - Drill holes hereb - Align dotted line with the transom bottom edge and fold under